Roofing Material And Method Of Making The Same

a technology of roofing materials and shingles, applied in the field of roofing materials, can solve the problems of reducing the cost and/or weight of shingles, and difficulty in achieving desired physical characteristics, and achieve the effect of enhancing visual appearance and great depth or thickness

Active Publication Date: 2011-08-04
BMIC LLC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0008]In one embodiment, the roofing material, which has reduced-particle size granules and may also have a reduced-thickness face coating, comprises a headlap and a butt section, with at least one of the headlap or butt section having at least two horizontal striations, wherein a first horizontal striation has granules of an average particle size and a second horizontal striation has granules of a different average particle size than the first horizontal striation. The different particle size of the striations creates a contrast between striations and may create a desired illusion of depth or thickness when the shingles are installed on a roof. The number of horizontal striations and their width may be varied to provide a greater illusion of depth or thickness. The color of the granules may also be varied to provide an enhanced visual appearance. In one embodiment, the roofing material is a single layer and the headlap section includes the at least two horizontal striations. In another embodiment, the roofing material is a laminated shingle including a backer strip, wherein the backer strip comprises the at least two horizontal striations.

Problems solved by technology

Attempts to reduce the cost and / or weight of shingles have met with difficulty in achieving desired physical characteristics, and particularly desired impact resistance.

Method used

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  • Roofing Material And Method Of Making The Same
  • Roofing Material And Method Of Making The Same
  • Roofing Material And Method Of Making The Same

Examples

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example 1

[0027]A fiberglass mat of about 1.63 lbs / csf was placed on a jumbo roll having a width corresponding to the width of the mat. The shingles were made in a continuous process where the glass mat was coated on the upper surface and lower surface with asphalt comprising a limestone filler. Fines were provided on the lower surface to seal the asphalt coating.

[0028]Table I below compares the weight of the face coat and granule layers for a control shingle and inventive shingle in accordance with the invention. For the inventive shingle, the thickness of the asphalt coating applied to the upper surface, i.e., the face coating, was 14 mils and had a weight of 12 lbs / csf. Grade 18 granules (IPS Mineral Products) having an average particle size of 23 mils were deposed on the face coating in a continuous process. A control shingle was also prepared in which the thickness of the face coating was 20 mils and had a weight of 17.5 lbs / csf. Grade 11 granules having an average particle size of 47 mi...

example 2

[0031]Two granule size distributions (version #1 and version #2) used to prepare the shingles of the present invention were compared with a control granule size distribution (control butt granules) used in conventional roofing shingles. At least 100 squares of both laminated and single layer strip shingles were manufactured using each of the granule size distributions by conventional shingle manufacturing processes. Each shingle was manufactured using the same coating weight or composition to demonstrate the affect of each granule distribution on the physical characteristics of the shingle. The control laminated shingles and the control strip shingles were manufactured by standard techniques using the butt granule size distributions.

[0032]Table IV indicates the retained percentage of granules for each sieve. Table V indicates the bulk density and specific gravity for each granule size distribution.

TABLE IVSievesControlUS meshSieveButtVersion #1Version #2(mils)OpeningGranulesGranules...

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Abstract

A roofing material comprising an upper surface and a lower surface, wherein the upper surface includes reduced-particle size granules and may further include a reduced-thickness face coating. The thickness of the upper surface is related to the particle size of the granules deposed on the face coating. A smaller particle size granule than those used in traditional roofing shingles is utilized in the upper surface which may allow for a reduced-thickness face coating while not sacrificing the retention of the granules on the surface of the roofing material or desired physical characteristics. The face coating may include a reduced amount of filler material, such as mineral fillers, than face coatings of traditional roofing materials.

Description

CROSS REFERENCE TO RELATED APPLICATIONS[0001]This application claims priority under 35 U.S.C. §119(e) to Provisional Application No. 61 / 299,664, filed on Jan. 29, 2010.FIELD OF THE INVENTION[0002]The present invention relates to roofing materials that have optimized granule and face coating layers which render the roofing materials better for the environment, cost effective and lighter than traditional roofing products while providing excellent physical and mechanical properties, such as fire resistance, impact resistance, tear strength and water shedding, and to methods of making the roofing materials.BACKGROUND OF INVENTION[0003]Roofing material has an upper surface intended to be exposed to weather and a lower surface facing in the direction opposite to the upper surface. A typical asphalt shingle has an asphalt-based substrate with granules deposed thereon. The granules are embedded in a layer of asphalt on the upper surface of the substrate, referred to herein as the face coati...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): E04D3/35
CPCY10T428/2438E04D3/35E04D1/26
Inventor KIIK, MATTIRODRIGUES, TOMMY F.RAILKAR, SUDHIR B.CHICH, ADEM
Owner BMIC LLC
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